CLASSIC LINE Operating Instructions 77 100..A00 Spring-applied multiple-disc brake Typen: 77 10013A00 77 10016A00 77 10019A00 77 10024A00 77 10025A00 77 10029A00 77 10033A00
Contents 1. General information... 3 1.1 Introduction... 3 1.2 Standards and directives... 3 1.3 Declaration of Incorporation (in accordance with Annex II, part 1, Section B of Machinery Directive 2006/42/EC)... 3 1.4 Manufacturer's liability... 3 2. Product description... 4 2.1 Operating principle... 4 2.2 Design... 4 3. Installation... 6 3.1 Mechanical installation... 6 3.2 Installation of accessories... 7 3.3 Electrical connection and operation... 8 3.3.1 DC power supply... 9 3.3.2 AC power supply... 9 3.3.3 Microswitch (19) connection... 11 3.4 Electromagnetic compatibility... 13 3.5 Set-up and start-up... 16 3.5.1 Functional checks... 16 3.5.2 Manual brake release... 16 3.6 M2 rated torque adjustments... 17 4. Maintenance... 17 4.1 Checks and service... 17 4.2 Microswitch (19) adjustment (only applicable to brakes with microswitch (19))... 19 4.3 Spare parts and accessories... 20 5. Condition at delivery... 20 6. Emissions... 21 6.1 Noise... 21 6.2 Heat... 21 7. Troubleshooting... 21 8. Safety... 22 8.1 Intended use... 22 8.2 General safety information... 22 8.2.1 Set-up... 22 8.2.2 Set-up and start-up... 23 8.2.3 Installation... 23 8.2.4 Operation... 23 8.2.5 Maintenance and repair... 23 8.3 Warning symbols... 24 9. Definitions... 24 10. Technical specifications... 26 11. Authorised repair shops for maintenance work... 28 Document information: Issued by: Kendrion (Villingen) GmbH Business unit: Industrial Drive Systems Replacement for document: - Replaces the issue dated: 30/12/2009 Type of document: Translation of original German operating Document status: Released instructions BA 77 100..A00 Designation of document: BA 77 100..A00 Englisch Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 2 von 29
1. General information 1.1 Introduction These Operating Instructions describe the operating principle and features of the 77 100..A00 series of spring-applied multiple-disc brakes. The safety information provided in this manual must be strictly observed during the set-up of the machine (e.g. motor) and during the start-up, operation and maintenance of the spring-applied brake. Should any queries arise with respect to torques, torque variations, installation position, wear, wear reserve, switching work, break-in conditions, release range, ambient conditions and the like, please contact Kendrion (Villingen) and ask for clarification before starting to use the brake. The springapplied multiple-disc brakes in the 77 100..A00 series are not ready-to-use devices, but are intended to be incorporated into or assembled with other equipment. 1.2 Standards and directives The state-of-the-art spring-applied brakes have been designed, built and tested in accordance with the requirements of DIN VDE 0580 concerning electromagnetic devices and components. Being classified as "electromagnetic components", spring-applied brakes are not subject to the Low Voltage Directive and must not bear a CE mark of conformity. The user is required to employ suitable switching devices and controls to ensure use of the brakes in accordance with EMC Directive 2004/108/EC. 1.3 Declaration of Incorporation (in accordance with Annex II, part 1, Section B of Machinery Directive 2006/42/EC) We hereby declare that the products below comply with the essential health and safety requirements specified in Annex I of Machinery Directive 2006/42/EC: Annex I General Principles, Annex I Sections 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.5.1 The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of Machinery Directive 2006/42/EC. The relevant technical documentation required for the partly completed machinery has been compiled in accordance with Annex VII, part B of Machinery Directive 2006/42/EC. The manufacturer undertakes to submit an electronic copy of the relevant technical documentation compiled for the partly completed machinery if reasonably requested by national authorities. Manufacturer: Kendrion (Villingen) GmbH Person authorised Dr. Uwe Gnauert Industrial Drive Systems to compile the Kendrion (Villingen) GmbH Wilhelm-Binder-Straße 4-6 documentation: Industrial Drive Systems 78048 Villingen-Schwenningen Wilhelm-Binder-Straße 4-6 Germany 78048 Villingen-Schwenningen Germany Standards and regulations: EN 60529 Enclosure protection ratings DIN VDE 0580 Electromagnetic devices and components Products: Electromagnetically released spring-applied multiple-disc brake 77 10013A00 77 10016A00 77 10019A00 77 10024A00 77 10025A00 77 10029A00 77 10033A00 Kendrion (Villingen) GmbH Industrial Drive Systems Villingen, 25 April 2016 by proxy... Dr. Uwe Gnauert (Head of Development at IDS) 1.4 Manufacturer's liability The manufacturer will not assume any responsibility for damage caused by failure to use the products in accordance with their intended use or by failure to observe safety information and other instructions provided in this manual. The information in this manual was correct and up-to-date before going to print. The information contained herein shall not entitle users to raise claims with respect to components purchased at an earlier date. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 3 von 29
2. Product description 2.1 Operating principle The spring-applied multiple-disc brake is designed to operate dry. The force generated by an electromagnetic field is utilised to overcome the braking effect produced by the spring force. The spring-applied multiple-disc brake engages in unpowered condition and releases when DC voltage is applied. Brakes equipped with a built-in rectifier (half-wave or bridge rectifier) can be connected directly to an AC power source. The form-fit connection between the friction disc and hub and the connection of the hub with the machine shaft (e.g. motor shaft) ensure that the torque generated by the spring-applied multiple-disc brake (brake torque) is reliably transmitted to the machine (motor). The brake can also be equipped with an optional hand release to allow the brake to be released manually. 2.2 Design The solenoid housing (1.1) of the spring-applied multiple-disc brake accommodates the firmly fitted field coil (1.2) whose connecting terminals are located in the connector box (25). The solenoid housing (1.1) also includes the compression springs (3), which press the disc pack (5) against the flange (11) over the pins (26) that are loosely guided within the armature (2). The disc pack (5) consists of the externally toothed outer discs (5.1), which are guided in the tooth ring (10), and of the internally toothed inner discs (5.2), which are guided on the hub (17). The braking effect of the spring-applied multiple-disc brake is generated as the disc pack (5) is pressed against the flange (11). The air gap 's' is adjusted by means of the sleeves (15) and tooth ring (10). The toothed inner discs (5.2) can be moved on the hub (17) in axial direction. The customerspecific connecting cable can be fed into the connector box (25) through a cable gland (14) (PG 11). When DC voltage is applied to the field coil (1.2) of the spring-applied multiple-disc brake, the spring force is overcome by the electromagnetic field force. This causes the armature (2) to be released and the braking effect to be neutralised. The shaft to be braked is not subjected to any axial force by the brake. When using brakes with hand release (21), openings must be provided in the part enclosing the brake (e.g. fan cover) so that the hand release lever can be installed. The hand release (21) allows the brake to be released manually (e.g. in case of power failure). Vertical brake operation is also possible. Bracing springs are provided in the outer discs (5.1) to ensure almost zero residual torque when the spring-applied multiple-disc brake is used in released (open) condition. Thanks to the centring diameters on the flange and housing sides (diameters d2 and d7), the spring-applied multiple-disc brake is ideal for applications with mounted transmitters (e.g. tachometer generators, encoders, etc.) after the cover (9) has been removed. Key to Fig. 5/1: 1.1 Solenoid housing 17 Hub with labyrinth seal 1.2 Field coil 18 Fixing surface 2 Armature 19 Microswitch 3 Compression spring 19.1 Cable gland 4 Stud 19.2 Microswitch cap 5 Disc pack 19.3 Locknut 5.1 Outer discs 19.4 Hexagon head cap screw 5.2 Inner discs 20 Protective cover 6 Sleeve 20.1 Machine screws for protective cover 7 Adjusting ring 21 Hand release 8 Set screw 21.1 Lever 9 Cover hood 21.2 Cam 10 Tooth ring 22 Fixing screws 11 Flange 23 Anti-adhesive disc 12 Sealing ring 25 Connector box 13 Machine screw 25.1 Connector box cover 14 Cable gland 25.2 Connecting terminal or rectifier 15 Sleeves 25.3 Machine screw 16 Rating plate 26 Pin Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 4 von 29
Fig. 5/1: Spring-applied multiple-disc brake 77 100..A00 Rated air gap Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 5 von 29
3. Installation 3.1 Mechanical installation The hub (17) must be slipped onto a shaft provided with a feather key to DIN 6885, sheet 1. The hub must be axially secured (by means of a shaft collar, circlip or the like). Make sure that the front face of the hub (17) is at the same height as the front face of the flange (11). The complete brake assembly must be slipped onto the hub (17) and centred using centring diameter d2 (see Classic Line specification sheet) of the flange (11). The inner discs (5.2), which are fixed in their position by the compression springs (3), are factory-centred to enable easy installation of the entire brake assembly on the hub. Make sure that the inner discs (5.2) can be easily moved along the hub (17). Hub position Size 13 16 19 24 25 29 33 L [mm] 24 26,5 30 45 45 52 58 L1 [mm] 0-1 0-1 0-1 0-1.2 0-1.2 0-1.2 0-1.2 MA [Nm] 4 8 8 12 12 18 28 MAZ [Nm] 4 8 8 12 12 18 28 Table 6/1: Hub dimensions (17); tightening torques of fixing screws (22) and machine screws (13) Check that the fixing surface (18) meets the following requirements before installing the brake: Axial runout relative to the shaft <0.1 mm (measuring radius = reference diameter) Surface roughness max. Rz16 Surface hardness min. 100 HB Material: steel, aluminium, cast iron with excellent thermal conductivity Absence of oil and grease Permitted mismatch of centring diameter (fixing surface (18)) relative to shaft <0.2 mm The spring-applied multiple-disc brake must be screwed to the fixing surface (18) by tightening the fixing screws (22) to the MA tightening torques specified in Table 6/1. The factory-adjusted rated air gap 's' cannot be changed. Note! Check that the inner discs (5.2) can be easily moved on the hub (17) by hand and that the mounted component parts, especially the friction surfaces and hub teeth, are free from grease. Attention! The MA tightening torque specified for the fixing screws (22) must be strictly observed. The screws (22) must be tightened evenly in diametrically opposite sequence. Note! The centring diameter d7 (see Fig. 5/1) is factory-aligned relative to the centring diameter d2 on the flange (11) with a maximum 0.2 mm radial runout. This enables easy attachment of a tachometer generator to the solenoid housing (1.1). Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 6 von 29
3.2 Installation of accessories Hand release (21): The cams (21.2) must be screwed into the bores provided on the circumference of the sleeve (6) making sure they are in the right position. The hand release lever (21.1) must be fixed to the square socket in the cams (21.2). The release forces F and the maximum permitted release forces (actuation forces) Fmax are specified in Table 7/1. Note! Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed when using brakes with hand release (21). Size 13 16 19 24 25 29 33 Release force F 1) [N] 15 40 50 55 55 90 180 Max. permitted release force (actuation force) Fmax [N] 22 60 75 85 85 140 270 Table 7/1: Release force F and maximum permitted release force (actuation force) Fmax of hand release (21) 1) Release force F (approx.) at the highest rated (standard) torque Note! When installing the cams (21.2) make sure that the cam surface points towards the armature (2) or tooth ring (10). If the hand release (21) is retrofitted to the brake at a later date, the sleeve (6) must be removed to allow two bores (see sketch below) to be drilled into the sleeve circumference. The bores are required to insert the cams (21.2) and must be offset by an angle of 180 relative to each other. The size and axial location of the bores are specified in Table 7/2. Caution! The brake torque can be neutralised manually by means of the hand release (21). Consequently, the brake must be installed in such a way that any unintentional actuation of the hand release (21) is excluded. Warning! Check that the mechanical hand release (21) is in a central position (see Fig. 5/1) when not in use. This is crucial to ensure reliable brake engagement. Otherwise, the full braking effect of the spring-applied multipledisc brake may not be reached. In this case, the machine (e.g. motor) must be stopped immediately and must not be restarted until correct operation of the hand release (21) and automatic return of the hand release lever in its central position (see Fig. 5/1) has been ensured. Size 13 16 19 24 25 29 33 Sleeve bore DM [mm] 7 +0.5 11 +0.5 11 +0.5 11 +0.5 11 +0.5 13 +0.5 15 +0.5 Distance LM [mm] 1 1.3 1 5.5 5.5 6.5 7.5 Table 7/2: Bore diameter DM and axial position LM of sleeve bores Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 7 von 29
3.3 Electrical connection and operation The spring-applied multiple-disc brake must be supplied with DC voltage. Connection to an AC power source is via a half-wave, bridge or overexcitation rectifier (25.2). Brakes with connector box (25) and built-in rectifier (25.2) can be connected directly to the AC mains. The contact assignment is shown in Fig. 9/1. Brakes equipped with connector box (25) and connecting terminal (25.2) must be connected directly to DC voltage. The customerspecific connecting cable must be connected to the terminals (25.2) or built-in rectifier (25.2) by means of a cable gland (14) (PG 11, clamping range 7.5 to 10 mm). Remove the cover (25.1) of the connector box (25) so that the individual strands of the connecting cable can be connected to the terminals (25.2) or to the contacts of the built-in rectifier (25.2). Brake versions with flying leads or connecting cable do not have a connector box. The wire ends of the flying leads or cable must be connected directly to the DC power source. Fig. 8/1: Connector box (25) with terminal (25.2) or rectifier (25.2) Rectifier series Rectifier type Rated input voltage range U1/VAC (40-60 Hz) Output voltage U2/VDC Max. output current R-load L-load I/ADC I/ADC 32 07.22B.0 half-wave 0-500 (10%) U1 0.445 1.6 2.0 32 07.23B.0 bridge 0-400 (10%) U1 0.890 1.6 2.0 32 17350E.. 32 17.2.B.. overexcitation bridgehalf-wave overexcitation bridgehalf-wave 48-120 (10%) 220-415 (10%) 480-525 (10%) 110-230 (10%) 220-415 (10%) U1 0.890 / U1 0.445 2.3 3 U1 0.890 / U1 0.445 Specific rectifier specification sheets must be observed! Table 8/1: Recommended rectifiers for single-phase AC voltage supply and for connection via terminal (25.2) 1.2 0.8 1.5 1.0 Attention! When fixing the cover (25.1) to the connector box (25), the MA tightening torques of the machine screws specified in Table 12/1 must be strictly observed. Damage to the flat seal between the connector box (25) and cover (25.1) must be avoided. When using brakes with built-in rectifier (25.2), the supply voltage is rectified by means of a half-wave rectifier (25.2). The built-in rectifier (25.2) can be wired in such a way that AC side switching (normal coupling time t1) or DC side switching (short coupling time t1) is possible (see Fig. 9/1). Various Kendrion rectifier types are available (see Table 8/1, list not exhaustive) for direct brake connection to an AC power source via the built-in connecting terminal (25.2). Depending on the brake size and torque, voltage ripple due to intermittent power supply may cause brake humming or incorrect brake operation. Perfect brake operation must be ensured by the user or system manufacturer by providing suitable electrical controls. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 8 von 29
Normal coupling time t1: Shorter coupling time t1: brake coil In case of DC side switching, AC side switching is also required. Fig. 9/1: Rectifier contact assignment for brakes with built-in rectifier (25.2) 3.3.1 DC power supply The figure to the right shows the voltage curve after the field coil (1.2) has been de-energised. M M 1 Attention! The peak voltage UVmax during disconnection without protective circuit may reach several thousand V in the millisecond region. This may cause irreversible damage to the field coil (1.2), switching contacts and electronic components. Sparking will occur on the switch during disconnection. Consequently, a protective circuit must be provided to reduce the current during disconnection and to limit the voltage. The maximum permitted overvoltage during disconnection is 1500 V. If Kendrion rectifiers are used (see Table 8/1), the protective circuit required for the built-in electronic components and field coil (1.2) is included in the rectifier. This does not apply to the external contacts required for DC side switching as there would be no galvanic isolation of the external contact. Attention! UB UVmax 0,9 x M 2 U U B t 11 operating voltage (coil voltage) disconnection voltage t 1 t t U Vmax Sensitive electronic components (e.g. logical components) may also be damaged by the lower voltage. 3.3.2 AC power supply Direct connection of the spring-applied multiple-disc brake to an AC power source is only possible if a rectifier is used. The coupling times vary depending on the switching type (DC side switching or AC side switching). Half-wave rectification: In case of half-wave rectification, the U2 coil voltage is lower by factor 0.445 than the rectifier input voltage. Half-wave rectifiers produce voltage with high residual ripple which, depending on the brake size, may slightly reduce the switching times when compared to bridge rectifiers. Due to the shorter switching times and the lower coil voltage, half-wave rectifiers are generally preferred to bridge rectifiers. However, brake humming may occur when small size brakes are used. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 9 von 29
Bridge rectification: Bridge rectifiers provide voltage with minimum residual ripple. This allows brake humming to be avoided even if small size brakes are used. In case of bridge rectification, the U2 coil voltage is lower by factor 0.89 than the rectifier input voltage. M 3~ 2 M 3~ 2 L1 L2 L3 - ~ ~ + U 1 L1 L2 L3 - ~ ~ + U 1 Connected in parallel with the machine (e.g. motor) AC side switching M 3~ 2 1 2 Rectifier Brake field coil - ~ ~ + U 3 Rectifier with DC side disconnection L1 L2 L3 3 DC side switching Fig. 10/1: Suggested brake connection (circuit diagram, AC or DC side switching and connected in parallel with the machine (e.g. motor)) AC side switching: The easiest wiring method is to connect the rectifier in parallel with the brake in the terminal box of the machine (e.g. motor). It must be considered, however, that the motor may act as a generator after AC voltage has been removed and thus extend the coupling time significantly (by factor 5 or over). The disconnection times remain unchanged. DC side switching: In case of DC side brake switching, an auxiliary contact is provided on the motor contactor, for example. This auxiliary contact is designed to interrupt the power supply on the DC side. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 10 von 29
Attention! In case of DC side switching, the brake must be provided with a protective circuit to avoid overvoltage. Additional protective elements (e.g. varistors, spark arresters, etc.) must be installed to avoid damage such as burns or welded contacts. Warning! Work on the brake must only be carried out by suitably qualified personnel. Make sure that no voltage is applied during brake connection. The specifications on the rating plate and the information provided in the circuit diagram in the terminal box or in the Operating Instructions must be strictly observed. Warning! The brake is a DC operated system. Permanent voltage variations on the power source of the electromagnetic brake must be limited to +/-10% of the rated voltage. The following checks must be carried out when connecting the brake: Check that the connecting cables are suitable for the intended use and for the voltage and amperage of the brake. Check that the connecting cables are secured with screws, clamps or other suitable fixtures to avoid interruptions in the power supply. Check that the connecting cables are long enough for the intended use and that suitable torsion, strain and shear relief features as well as bending protections are provided. Check that the PE conductor (only for protection class I) is connected to the earthing point. Check that no foreign matter, dirt or humidity is trapped inside the terminal box. Check that unused cable entries and the terminal box are suitably sealed to ensure compliance with the protection class requirements to EN 60529. 3.3.3 Microswitch (19) connection If brakes are equipped with a microswitch (19) to control the release status (released/engaged) of the springapplied multiple-disc brake, the microswitch (19) must be tied into the control circuit of the machine (e.g. motor) (see suggested brake and microswitch (19) connection in Fig. 12/1). This is to ensure that the microswitch (19) prevents any start-up of the machine (e.g. motor) before the spring-applied multiple-disc brake has been released. If the brake has a protective microswitch cover (20), the cover (20) must be removed to allow the microswitch connecting cable to be installed. After removal of the cover (20), the microswitch cap (19.2) can be loosened and taken off. The customer-specific connecting cable for the microswitch (19) can be fed into the microswitch connector box through the cable gland (19.1) (PG 9). The cable strands must be connected with the NO (normally open) and C (common) contacts by means of the microswitch connecting terminals. After completion of connection, the cap (19.2) and protective cover (20) must be reinstalled. The optional microswitch (19) must be ordered together with the brake as it cannot be retrofitted to the brake at a later date. The microswitch (19) is factory-adjusted prior to shipment of the spring-applied multiple-disc brake. Attention! When installing the protective cover (20) and cap (19.2) of the microswitch (19) and the cover (25.1) provided for the connector box (25), the machine screws must be tightened to the MA tightening torques specified in Table 12/1. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 11 von 29
MA tightening torque [Nm] of machine screws (20.1) for protective cover (20) MA tightening torque [Nm] of machine screws (19.5) for microswitch cap (19.2) MA tightening torque [Nm] of machine screws (25.3) for connector box cover (25.1) Size 13 16 19 24 25 29 33-5 5 5 5 - - 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1.6 1.6 1.6 1.6 1.6 1.6 1.6 Table 12/1: Tightening torques of machine screws for protective cover (20), microswitch cap (19.2) and connector box cover (25.1) M 3~ 4 3 2 - ~ ~ + U 5 1 N L1 L2 L3 1 Rectifier 4 Microswitch S (19, NO contact) 2 3 Brake field coil (1.2) Brake control relay (contactor) 5 Control relay (contactor) of microswitch S (19) Fig. 12/1: Suggested connection of brake with microswitch (19) (circuit diagram, AC side switching) Note! Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed when using brakes with microswitches (19). Warning! The motor circuit must be protected in such a way that no accidental motor start-up can occur when the microswitch (19) contact closes. Note! The suggested wiring of the spring-applied multiple-disc brake with microswitch (19) shown in Fig. 12/1 is based on the general recommendations for the connection of electromagnetic components used in electric machinery (e.g. motors) without load torque impact. When the brake is used for applications during which a load torque is generated, the system user is responsible to ensure correct and safe wiring of the microswitch (19) and brake. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 12 von 29
3.4 Electromagnetic compatibility As required by the German Electromagnetic Compatibility Act (EMVG), electromagnetic compatibility is essential to ensure immunity to external electromagnetic fields and conducted interference. Furthermore, the emission of electromagnetic fields and line-conducted interference during brake operation must be minimised. Since the brake features depend on the circuitry and operation, a declaration of conformity with the applicable EMC standard can only be furnished for the wiring type, but not for a specific brake. The spring-applied multiple-disc brakes in the 77 100..A00 series are designed for industrial applications to which the following EMC standards apply: Generic Immunity Standard VKE 0839, part 6-2 (EN 61000-6-2), and Generic Emission Standard VDE 0839, part 81-2 (EN 50081-2). Other applications may be subject to different generic standards which must be considered by the manufacturer of the overall system. The requirements in terms of electromagnetic compatibility of devices and components are determined by basic standards derived from the generic standards. Brake wiring recommendations will be provided in the following sections to ensure compliance with the individual basic standards that are relevant for industrial brake use and other applications. Please refer to the specification sheets for additional information on electromagnetic compatibility, especially with respect to the recommended electronic rectifiers specified in Section 3.3. Immunity according to EN 61000-4: EN 61000-4-2 Electrostatic discharge: The spring-applied multiple-disc brakes in the 77 100..A00 series comply at least with severity level 3 without requiring additional measures. The recommended rectifiers specified in Section 3.3 conform to severity level 3 without additional measures. When using brakes with built-in rectifier, the rectifier conforms to severity level 3 without requiring additional measures. EN 61000-4-3 Electromagnetic fields: The brakes comply at least with severity level 3 without requiring additional measures. The recommended rectifiers conform to severity level 3 without additional measures. When using brakes with built-in rectifier, the rectifier conforms to severity level 3 without requiring additional measures. EN 61000-4-4 Fast transients (burst): The brakes comply at least with severity level 3 without requiring additional measures. The recommended rectifiers conform to severity level 3. When using rectifiers of the 32 17.2.B.. series, which conform to severity level 3, a temporary slight voltage increase may occur which, however, will not interfere with the rectifier function. When using brakes with built-in rectifier, the rectifier conforms to severity level 3 without requiring additional measures. EN 61000-4-5 Surge: The brakes comply at least with severity level 3 without requiring additional measures. The recommended rectifiers conform to severity level 3 without additional measures. When using brakes with built-in rectifier, the rectifier conforms to severity level 3 without requiring additional measures. EN 61000-4-9 Pulse magnetic fields, EN 61000-4-10 Damped oscillatory magnetic fields: Since the operating magnetic fields of the electromagnetic brakes are stronger many times over than interference fields, the brake function will remain unaffected. The brakes comply at least with severity level 4. The recommended rectifiers conform to severity level 3 without additional measures. When using brakes with built-in rectifier, the rectifier conforms to severity level 3 without requiring additional measures. EN 61000-4-11 Voltage dips, short interruptions, and short supply voltage variations: a) Voltage interruptions: Brakes that comply with the requirements of DIN VDE 0580 are de-energised after the specified switching times at the latest. The switching time depends on the control and mains conditions (e.g. generator effect of running down motors). Voltage interruptions of shorter duration than the response delay specified by DIN VDE 0580 will not cause any malfunctions. The user must ensure that any damage is avoided (e.g. motor start-up before the brake has been released caused by phase failure in the case of two-phase energised motors or by the slipping of an electromagnetically engaged system due to torque drop). The functional reliability of the electromagnetic brake and its electronic accessories remains unaffected provided that any damage is avoided. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 13 von 29
b) Voltage dips and short supply voltage variations: Electromagnetically released systems: Voltage dips and supply voltage variations to below 60% of the rated voltage and lasting longer than the response delay specified by DIN VDE 0580 may cause the brake to be de-energised temporarily. Damage as described under a) above must be avoided by the user by taking adequate precautions. Electromagnetically engaged systems: Voltage dips and supply voltage variations to below the minimum tolerance threshold will cause torque reductions. The user is required to take adequate precautions to avoid consequential damage. Radio interference suppression in accordance with EN 55011: The brakes and the recommended electronic rectifiers are classified as Group 1 equipment in accordance with EN 55011. As far as the emissions from this equipment are concerned, one distinguishes between field guided radiated interference and line-conducted interference. a) Radiated interference: When operated with DC voltage or rectified 50/60 Hz AC voltage, all brakes comply with the limit values applicable to Class B equipment. b) Conducted interference: When connected to a DC power source, the electromagnetic brakes meet the limit values applicable to Class A equipment. If the brakes are connected to a 50/60 Hz AC power source and equipped with electronic rectifiers or other electronic controls, interference suppression measures as shown in Fig. 14/1 must be R L taken to ensure compliance with the limit values applicable to Class A equipment. Interference U suppression capacitors should be used which must be dimensioned to suit the connection data of the electromagnetic components and the specific mains conditions. The recommended rectifiers specified in C Section 3.3 are CE mark certified in accordance with the EMC Directive. They have built-in interference suppression components and comply at least with the requirements of EN 55011 for Class A equipment, Fig. 14/1 unless otherwise specified in the specification sheet. When brakes are used with the specified rectifiers or with other types of rectifiers, the recommended values listed in Table 15/2 should be observed. Interference suppression components should be installed as close as possible to the consumer. Interference caused during switching operations of the electromagnetic component is generally attributable to the inductive load. Where necessary, assemblies designed to limit the disconnection voltage (e.g. anti-parallel diode) or voltage limiting components (e.g. varistors, suppressor diodes, resistance diodes and the like) can be installed. However, such components will inevitably change the switching times of the brake and increase the generated noise level. The rectifiers specified in Section 3.3 are equipped with free-wheel diodes and/or varistors to limit the disconnection voltage. In case of DC side switching, a varistor rated for the type-specific maximum operating voltage and connected in parallel with the field coil (1.2) limits the peak voltage to the values specified in Table 15/2. If the brake is used in connection with other electronic accessories, the user is responsible to ensure compliance with EMC requirements. Compliance with applicable standards concerning the design and operation of components, sub-assemblies or equipment employed shall not relieve the user and manufacturer of the overall system from their obligation to furnish proof of conformity of the overall system with such standards. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 14 von 29
Rectifier type Bridge rectifier 32 07.23B.0 Half-wave rectifier 32 07.22B.0 Overexcitation rectifier 32 17350E.. Overexcitation rectifier 32 17.2.B.. Table 15/1 Rated input voltage range U1/VAC (40-60 Hz) DC at L-load (ADC) up to 400 (+10%) up to 2.0 up to 500 (+10%) up to 2.0 48-120 (10%) 220-415 (10%) 480-525 (10%) 110-230 220-415 up to 3 up to 1.5 up to 1.0 Capacitor (nf(vac)) no additional interference suppression measures required no additional interference suppression measures required no additional interference suppression measures required no additional interference suppression measures required Table 15/2 Rectifier input voltage (max.) (VAC) Recommended disconnection voltage for DC side switching (V) 250 700 440 1200 550 1500 Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 15 von 29
3.5 Set-up and start-up Warning! The functional check of the brake must not be performed unless the machine (e.g. motor) has been switched off and secured against accidental or unintentional start-up. 3.5.1 Functional checks The following checks must be carried out: Check compliance with the specifications provided on the rating plate with respect to the mounting position and protection class. After connection of the brake, an operational test must be performed to check that the friction disc (5) runs smoothly. For this purpose, turn the shaft (while the brake is energised and the machine (e.g. motor) is unpowered). Install the required guards and protections after completion of installation. Warning! Before starting the machine (e.g. motor) test run without driven components, the feather key (if used) must be secured in such a way that it cannot be hurled out. The shaft must not be exposed to load torques. Before the machine (e.g. motor) is re-started, the brake must be de-energised. Caution! The brake surface temperature may rise to over 100 C. Heat-sensitive parts such as conventional cables or electronic components must not be fixed to or be in contact with these surfaces. If necessary, suitable protections and hand guards must be installed to avoid accidental contact with hot surfaces! If the shaft needs to be turned during set-up operations while the machine (e.g. motor) is switched off, the brake must be released electromagnetically or by means of the hand release lever (21). Caution! High-voltage tests performed during brake installation within an overall system or during start-up must be carried out in such a way that damage to the built-in electronic accessories is avoided. The limits for highvoltage tests and follow-up tests specified by DIN VDE 0580 must be observed. Attention! Check that the brake has been connected in accordance with the specifications provided on the rating plate before it is put into operation. Even short-term operation outside the specified supply voltage limits may cause irreversible damage to the brake or electronic accessories. Such damage may not be apparent immediately. DC side brake switching without protective circuit as described in Section 3.4 will cause damage to electronic rectifiers, electronic accessories, switching contacts and to the field coil (1.2). 3.5.2 Manual brake release The spring-applied multiple-disc brake can be released "manually" by means of a mechanical hand release (21) (accessories). In case of failure of the regular power supply, it is also possible to use a commercial UPS (e.g. UPS battery system) for the electrical release of the brake. For this purpose, the brake user is required to install a UPS system that complies with the voltage specifications given on the brake rating plate. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 16 von 29
Warning! Manual release (inching mode) of the spring-applied multiple-disc brake (e.g. for maintenance operations on the machine (e.g. motor) or in case of failure of the regular power supply and use of a UPS system) must be performed with extreme caution. If the drive system is unbalanced, the load torque may accelerate the drive. The brake user is required to take adequate precautions to ensure that no hazardous situations are caused by the load torque when the brake is released and engaged in inching mode. 3.6 M2 rated torque adjustments The brakes are factory-adjusted to the M2 rated torque (as specified in the purchase order). The M2 rated torque is specified on the rating plate (16) of the brake. The adjusting ring clearance b3 is marked on the collar of the brake back near the set screw (8). It can be changed by tightening or loosening the adjusting ring (7) by means of a pin spanner. The corresponding changes in the M2 rated torque are specified in Table 17/1. The adjusting ring clearance b3 must remain within the specified minimum and maximum values (see Table 17/1). Adjusting ring clearance Size 13 16 19 24 25 29 33 M2/mm [Nm] 6.25 13.6 33.3 50 95 120 218 b3min [mm] 3 2.4 3.8 2.8 3.1 1.4 1.9 b3max[mm] 4.6 4.6 5.6 5.2 5 3.4 4.1 Table 17/1: Change in the M2 rated torque from 1 mm axial adjustment of the adjusting ring (7); adjusting ring clearance b3 limit values Attention! After having tightened or loosened the adjusting ring (7), the ring (7) must be locked with the set screw (8). The tightening torque to be applied is MA = 3 Nm. The adjusting ring (7) must be turned in such a way that the set screw (8) can be inserted between the studs (4). 4. Maintenance 4.1 Checks and service The spring-applied multiple-disc brake does not require any particular maintenance except that the air gap 's' must be measured at regular intervals. After the sleeve (6) has been removed, the air gap 's' (see Table 26/1 "Technical specifications" for rated air gap) between the armature (2) and the built-in anti-adhesive disc (23) can be checked by means of a feeler gauge while the brake is de-energised. Precise measurement of the air gap requires the use of two screwdrivers arranged at an angle of 180 relative to each other to press the armature (2) towards the solenoid housing (1.1) until it touches the stud (4). When the maximum air gap smax has been reached (see Table 26/1), the disc pack (5) of the spring-applied multiple-disc brake must be replaced. The individual discs must be installed as shown in Fig. 18/1 and Fig. 18/2. For this purpose, loosen the fixing screws (22) and remove the brake from the hub (17). Remove the cover hood (9) and screw out the adjusting ring (7) after having loosened the set screw (8). Loosen the machine screws (13) and remove the flange (11) from the tooth ring (10). Remove the worn disc pack (5) and replace it by a new one. Before reassembling the brake components, clean all parts (flange (11), armature (2) and tooth ring (10)) with grease-free cleaners. Screw the flange (11) with the sleeves (15) and tooth ring (10) to the core element of the spring-applied multiple-disc brake by means of the machine screws (13). Screw in the adjusting ring (7) until the b3 clearance (marked on the collar of the brake back) has been reached and secure it with the set screw (8). Install the cover hood (9) as shown in Fig. 5/1. Install and connect the spring-applied multiple-disc brake as described in Sections 3.2 and 3.3. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 17 von 29
Size 13 + 16 Size 19 + 24 (hatched disc not used with size 24) Fig. 18/1: Disc arrangement (sizes 13 to 24) Disc (without springs) Disc (springs pointing upwards) Front Disc (springs pointing downwards) Rear Size 33 Fig. 18/2: Disc arrangement (sizes 25 to 33) Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 18 von 29
Attention! When installing the spring-applied multiple-disc brake, it is crucial that the fixing screws (22) be tightened applying the MA tightening torque specified in Table 6/1. The machine screws (13) must be tightened to the MAZ torque specified in Table 6/1. The set screw (8) of the adjusting ring (7) must be tightened to MA = 3 Nm. After the disc pack (5) has been replaced, the air gap 's' must be checked (see Table 26/1 for information on the rated air gap). Attention! After the adjusting ring (7) has been screwed in, the set screw (8) must be located directly beside the marking of the adjusting ring clearance b3. Check that the set screw is not positioned on a stud (4). Attention! Depending on its operating condition, it may no longer be possible to release the spring-applied multiple-disc brake when the maximum air gap smax (see "Technical specifications" in Table 26/1) has been exceeded. In this case, the braking effect cannot be neutralised. This may cause thermal overloading of and irreversible damage to the brake if the machine (e.g. motor) is started before the brake has been released. Thermal overloading of the machine (e.g. motor) may occur if the machine (e.g. motor) is not started while the brake is still engaged. Caution! If a hand release lever (21) is fitted to the brake and the maximum air gap smax (see "Technical specifications" in Table 26/1) has been exceeded, the hand release lever (21) will limit the axial movement of the armature (2). This will cause the torque to be reduced down to zero. Whenever carrying out maintenance work, check the degree of wear of the disc pack (5) and the air gap 's' and replace the disc pack (5) well before the maximum air gap smax (see "Technical specifications" in Table 26/1) is reached. 4.2 Microswitch (19) adjustment (only applicable to brakes with microswitch (19)) The spring-applied multiple-disc brake must be released electrically to allow the microswitch (19) to be adjusted. Unscrew the locknut (19.3) and turn the hexagon head cap screw (19.4) clockwise until the microswitch (19) switches (slight audible click or contact closure between the NO and C contacts). If the microswitch (19) is in ON position, it must be turned anticlockwise to OFF. After the changeover position has been reached, continue to turn the hexagon head cap screw (19.4) as follows: Size 13 brakes: by 50 / Size 16 24 brakes: by 70 Tighten the locknut (19.3). Make sure the position of the hexagon head cap screw (19.4) remains unchanged when tightening the locknut. Switch the brake on and off to check that the microswitch is in perfect working order. Fig. 19/1: Microswitch (19) adjustment Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 19 von 29
Warning! The motor circuit must be protected in such a way that no accidental motor start-up can occur when the microswitch (19) contact closes. Warning! Whenever inspection and maintenance work is carried out, check that the machine (e.g. motor) is secured against accidental or unintentional start-up. no load torque is applied to the shaft. the lock provided to prevent accidental start-up of the machine (e.g. motor) is removed after completion of inspection and maintenance work. all friction surfaces are free from grease and oil. An oily or greasy disc pack (5) cannot be cleaned. the inner discs (5.2) and outer discs (5.1) have not swollen or turned vitreous. 4.3 Spare parts and accessories Designation, order number Size Hand release (21) Fixing screw (22) Disc pack (5) Type A A S 13 71 10113E00940 304035 77 10013A00850 16 71 10116E00940 304060 77 10016A00850 19 71 10119E00940 304062 77 10019A00850 24 71 10124E00940 304088 77 10024A00850 25 71 10124E00940 304090 77 10025A00850 29 71 10129E00940 304123 77 10029A00850 33 71 10133E00940 150 77 10033A00850 Table 20/1: Spare parts (S) and accessories (A) 5. Condition at delivery Upon receipt of the shipment, the spring-applied brake must be checked for transit damage before storage. Ordered accessories (e.g. hand release, fixing screws) are delivered together with the brake. The springapplied multiple-disc brake is delivered ready for mounting with factory-adjusted M2 rated torque and factoryadjusted air gap 's' (adjustment with sleeves and tooth ring). Note! If the brake is not installed immediately upon delivery, it must be stored in a dry, dust-free and vibration-proof place. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 20 von 29
6. Emissions 6.1 Noise The spring-applied multiple-disc brake produces switching noise during engagement and release. The noise level is determined by the installation conditions, circuitry (e.g. with overexcitation) and air gap. Depending on the installation position, operating conditions and quality of the friction surfaces, clearly audible vibrations (squeaking) may be produced during braking. 6.2 Heat Braking operations and gradual heating of the field coil cause the solenoid housing temperature to increase substantially. Under adverse conditions, the surface temperature may rise to well over 100 C. Caution! Risk of burns in case of contact with hot surfaces! Suitable covers and hand guards must be installed to provide protection against accidental contact. 7. Troubleshooting Fault Cause Corrective actions Brake release failure Delayed brake release Brake engagement failure Air gap too large Check the air gap. Install a new disc pack, if necessary. No voltage applied to brake Check the electrical connection and correct faults, if found. Voltage applied to field coil too low Check the field coil supply voltage and correct faults, if found. Armature plate blocked mechanically Eliminate mechanical blocks. Damaged rectifier Check the rectifier and replace it, if necessary. Damaged field coil Check the field coil resistance. Install a new brake, if necessary. Discs thermally overloaded Install a new disc pack. Install a new brake, if necessary. Air gap too large Check the air gap. Install a new disc pack, if necessary. Voltage applied to field coil too low Check the field coil supply voltage and correct faults, if found. Voltage applied to field coil in unpowered condition too high (residual voltage) Armature plate blocked mechanically Eliminate mechanical blocks. Check whether residual voltage is applied to the field coil and correct faults, if found. Delayed brake engagement Voltage applied to field coil too high Check the field coil supply voltage and correct faults, if found. Brake torque too low Microswitch failure (only brake types with microswitch) Air gap too large Check the air gap. Install a new disc pack, if necessary. Oily or greasy discs Check the discs. Install a new disc pack, if necessary. Axial armature movement blocked by Check the air gap. Install a new disc pack, if necessary. hand release Broken compression spring Check the spring force. Install a new brake, if necessary. Damaged microswitch Install a new microswitch. Adjustment error of microswitch switching point Readjust the microswitch switching point. Table 21/1: Possible faults, causes and corrective actions (list not exhaustive) Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 21 von 29
8. Safety The brakes described in these Operating Instructions have been designed and built on the basis of an analysis of hazards and in accordance with the requirements of the applicable harmonised standards and technical specifications. They correspond to the state of the art and provide maximum safety. However, safety hazards can only be avoided if the user of the equipment takes adequate precautions and makes sure that the safety instructions are strictly adhered to. The user is required to ensure that: the brakes are only used in accordance with their intended use (see Section 2 "Product description"). the brakes are in perfect working order and checked at regular intervals. a complete and fully legible copy of these Operating Instructions is kept available at the place of use of the brakes at all times. start-up, maintenance and repair work is only done by authorised and suitably qualified personnel. such personnel are kept informed on all relevant occupational safety and environmental protection issues and familiar with these Operating Instructions and with the safety information contained herein. the brakes are not exposed to other strong magnetic fields. 8.1 Intended use The brakes described in these Operating Instructions are intended to be assembled with machines, in particular electric motors, for use on industrial plant. Operation in potentially explosive atmospheres or locations requiring flame-proofing is not allowed. The brakes must be used in accordance with the operating requirements detailed in this manual. The rated power limits specified herein must not be exceeded. 8.2 General safety information Brakes fitted to motors feature hazardous live components and rotating parts and may exhibit hot surfaces. Any work associated with the transport, connection, start-up and periodical maintenance of the brakes must be carried out by authorised and suitably qualified personnel (in accordance with VDE 0105; IEC 364). Failure to observe safety, operating and maintenance instructions may cause serious personal injury and severe damage to the equipment. Whenever special measures are required in accordance with the instructions contained herein, such measures should be agreed with the brake manufacturer before the machinery into which the brake is to be incorporated is set up. Should any queries arise with respect to torques, torque variations, installation positions, wear, wear reserve, switching work, break-in conditions, release range, ambient conditions and the like, please contact Kendrion and ask for clarification before using the brake. Retrofitting or modification work to be carried out on the brake is subject to the approval from Kendrion (Villingen). Accident prevention regulations applying to the specific field of application of the brake must be strictly observed. The brakes described in this manual are not designed for use as "safety brakes". This means that torque reductions caused by factors beyond the user's control cannot be excluded. 8.2.1 Set-up Requirements in terms of the permitted number of switching operations per hour and the maximum switching work per switching operation specified in the technical specifications must be strictly observed during the setup of machines and plant (inching mode). Failure to observe these instructions may irreversibly diminish the braking effect and cause malfunctions. The operating conditions at normal rating specified in these Operating Instructions refer to DIN VDE 0580. The protection type is based on EN 60529. In case of deviations from these requirements, special precautions may have to be taken after consultation with the brake manufacturer. If vertical brake operation is envisaged, any special requirements must be agreed with the manufacturer. Bear in mind that the friction disc may freeze if ambient temperatures fall below -5 C or if the brake remains unpowered for prolonged periods of time. In this case, special precautions must be taken after consultation with the manufacturer. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 22 von 29
8.2.2 Set-up and start-up The brakes must not be put into operation when: power supply cables/wires or connections are damaged. the solenoid housing or coil sheath is damaged. other defects are suspected. 8.2.3 Installation The voltage and voltage type specified on the rating plate must be strictly observed when connecting the brakes described in these Operating Instructions. Sufficient heat dissipation must be ensured when the brake is fitted to or incorporated into other equipment. Adequate precautions must be taken to avoid overvoltage during disconnection or voltage peaks. The magnetic field of the products may cause interference outside the brake or even feedback to the brake in case of adverse installation conditions. Should you have queries concerning mounting and fitting conditions, please contact the brake manufacturer and ask for clarification. Adequate safety measures (DIN VDE 0848, part 4; DIN 31000/VDE 1000; DIN VDE 0100, part 0420) must be taken by the brake user to avoid hazards to persons and animals or damage to equipment caused by: direct or indirect effects of electromagnetic fields, heated components, mobile parts. 8.2.4 Operation Make sure that live components such as plug contacts or the field coil are not exposed to water. The brake cable connections must not be crushed, squeezed or exposed to mechanical loads. Make absolutely sure that the friction surfaces of the friction elements are not contaminated with grease, oil or other liquids to avoid substantial torque reduction. Bear in mind that the original torque cannot be restored even if the friction surfaces are cleaned after contact with liquids. The gradual brake wear and the resulting torque reduction of spring-applied brakes must be taken into consideration during set-up. Due to the diverse ambient conditions in which the brakes may be used, always check that the brake is in perfect working order before start-up. Torque reductions cannot be excluded if the brake is used for applications where only minimum friction work is required. In such cases, the user should ensure that the brake occasionally performs sufficient friction work. Operation of the brake as pure holding brake without friction work is only allowed after prior consultation with the manufacturer. If brakes equipped with hand release lever are used, the lever must only be moved up to the release position in order to avoid deformation or breaks. Note! The maximum air gap smax (see Table 26/1 "Technical specifications") must not be exceeded throughout the entire brake service life. (Please refer to Section 4 "Maintenance" for details.) 8.2.5 Maintenance and repair Repair work must only be carried out by suitably qualified personnel (definition to IEC 364). Failure to perform repairs according to requirements may cause serious personal injury or equipment damage. Make sure that no voltage is applied to the brakes when carrying out maintenance work. Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 23 von 29
8.3 Warning symbols Personal injury or equipment damage Symbol / Term Warns against... Potential risks and hazards Danger imminent personal injury fatal accidents or serious injury Warning potential risk of serious personal injury fatal accidents or serious injury Caution potential risk of personal injury minor injury Attention potential risk of equipment damage damage to the components or other equipment Information Symbol / Term Provides information on Note the safe use and operation of the product 9. Definitions (based on: DIN VDE 0580 July 2000, not exhaustive) Switching torque M1 Rated torque M2 Transmissible torque M4 Residual torque M5 Load torque M6 Switching work W Maximum switching work Wmax Switching power P Maximum switching power Pmax Coil ON time t5 Coil OFF time t6 Total cycle time t7 Duty cycle Switching operation Switching frequency Z Response delay during coupling t11 torque acting on the shaft during brake or clutch slip switching torque specified by the manufacturer to identify the brake. The rated torque M2 is the mean value of at least 3 measurements of the maximum switching torque M1 after completion of the transient response. highest torque that can be applied to the engaged brake or clutch without causing the brake/clutch to slip torque transmitted by the released brake or clutch torque acting on the drive of the engaged brake or clutch; determined by the power requirement of the driven machine at a given speed heat generated by friction inside the brake or clutch as a result of the switching operation maximum switching work to which the brake or clutch may be exposed switching work converted into heat per unit of time maximum permitted switching work converted into heat per unit of time time between power on and power off time between power off and power on coil ON time plus coil OFF time percentage relationship of coil ON time to total cycle time one complete switching on and off operation number of regular switching operations per hour time between power off (releasing systems) or power on (engaging systems) and beginning of torque increase Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 24 von 29
Rise time t12 Coupling time t1 Response delay during disconnection t21 Fall time t22 Disconnection time t2 Slip time t3 Making time t4 Operating condition at operating temperature Overtemperature 31 Limit temperatures of coil insulating materials Rated voltage UN Rated current IB Rated power PN Rated power at 20 C winding temperature PB time it takes to reach 90% of the M2 rated torque from the beginning of the torque increase response delay t11 plus rise time t12 time between power on (releasing systems) or power off (engaging systems) and beginning of torque decrease time it takes for the torque from the beginning of the torque decrease to fall to 10% of the M2 rated torque response delay t21 plus fall time t22 time from the beginning of the torque increase up to the end of the braking process (brakes) or until the synchronisation torque M3 has been reached (clutches) response delay t11 plus slip time t3 (braking or acceleration time) condition at which the steady-state temperature is reached. The operating temperature corresponds to the overtemperature according to DIN VDE 0580 plus the ambient temperature. Unless otherwise specified, the ambient temperature is 35 C. difference between the temperature of the electromagnetic device or a part thereof and the ambient temperature in accordance with DIN VDE 0580. The individual insulating materials are classified by insulation classes to DIN IEC 85. supply voltage specified by the manufacturer for voltage windings to identify the device or component amperage determined by the manufacturer for the specified operating conditions. Unless otherwise specified, the rated current refers to the rated voltage, 20 C winding temperature and to the rated frequency for a given operating mode of voltage windings. power value to identify the device or component determined from the rated current of voltage-controlled devices and components and the R20 resistance at 20 C winding temperature Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 25 von 29
10. Technical specifications Product built and tested to DIN VDE 0580 Size 13 16 19 24 25 29 33 Rated (standard) torque range M2 [Nm] 17-25 25-50 50-100 100-200 150-300 200-400 400-800 Max. reachable rated torque M2max [Nm] 279 55 110 220 330 440 880 Residual torque M5 [Nm] 0.05 0.1 0.2 0.5 0.7 1 2 Max. speed nmax [rpm] 4500 3800 3200 3000 3000 3000 2500 Max. switching power (attached brakes) Pmax 460 570 640 700 740 1000 1300 [kj/h] Max. switching power (built-in brakes) Pmax [kj/h] 720 930 1090 1190 1210 1700 1980 Rated power PN [W] 38 60 75 109 109 185 230 Coupling time t1 [ms] 50 (M 2 =25Nm) 80 (M 2 =50Nm) 100 (M 2 =100Nm) 200 (M 2 =200Nm) 250 (M 2 =300Nm 300 (M 2 =400Nm 450 (M 2 =800Nm Disconnection time t2 [ms] 160 200 270 330 350 480 600 (M 2 =25Nm) (M 2 =50Nm) (M 2 =100Nm) (M 2 =200Nm) (M 2 =300Nm (M 2 =400Nm (M 2 =800Nm Moment of inertia hub and inner discs J [kgcm 2 ] 6,25 20 40 95 135 250 650 Weight m [kg] 5.4 10.2 14.8 31.1 32.6 58.3 93.4 Rated air gap s [mm] 0.5 +0.2 0.6 +0.2 0.6 +0.3 0.7 +0.3 0.9 +0.3 1.1 +0.3 1.1 +0.3 Max. air gap smax 1) [mm] 1 1.7 1.7 1.8 1.8 2.3 2.5 Standard rated voltage [VDC] Insulation class 24, 102, 178 Pollution degree 2 Protection Brake type Table 26/1: Technical specifications F IP 54 IP 55 (when installed under motor fan cover) service brake 1) Max. air gap smax at maximum (standard) rated torque and at 70% of rated current. Information on max. air gap smax at maximum reachable rated torque M2max to be requested from manufacturer. Size 13 16 19 24 25 29 33 Speed n [rpm] 250 250 250 100 80 80 80 Coil ON time t5 [s] 4 8 14 10 10 10 10 Coil OFF time t6 [s] 1 1 1 1 1 1 1 Break-in period ttot [min] approx. 2 approx. 2 approx. 2 approx. 2 approx. 2 approx. 2 approx. 2 Table 26/2: Break-in process parameters for the spring-applied multiple-disc brake Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 26 von 29
1000000 1000000 J J 100000 W max. 10000 Size Gr. 33 Size Gr. 29 Size Gr. 25 Size Gr. 24 Size Gr. 19 Size Gr. 16 Size Gr. 13 100000 W max. 10000 Size Gr. 33 Size Gr. 29 Size Gr. 25 Size Gr. 24 Size Gr. 19 Size Gr. 16 Size Gr. 13 1000 1000 100 100 10 1 10 100 1000 h -1 10000 Z 10 1 10 100 1000 h -1 10000 Z Fig. 27/1: Max. switching work Wmax per switching operation as a function of the number of switching operations per hour Z (attached brakes; values based on n=1500 rpm) Fig. 27/2: Max. switching work Wmax per switching operation as a function of the number of switching operations per hour Z (built-in brakes; values based on n=1500 rpm) Technical specifications 250 VAC, 25 A (resistive load) 250 VAC, 8 A (inductive load, cos = 0.6) Switching capacity 24 VDC, 10 A (resistive load) 24 VDC, 6 A (L/R = 50 ms) Min. switching power 12 VDC, 10 ma Mechanical service life [switching operations] 3 x 10 7 Contact type normally open contact Temperature range [ C] 20 to +80 Protection IP 67 Table 27/1: Microswitch specifications (only for brakes with microswitch) Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 27 von 29
Explanations on the technical specifications: Wmax (maximum switching work) is the switching work that must not be exceeded during braking operations at max. 1500 rpm. Braking operations at >1500 rpm substantially reduce the maximum permitted switching work per switching operation. Such operation is only allowed after prior consultation with the manufacturer. The maximum switching power Pmax is the switching work W that can be converted by the brake per hour. In case of applications where the number of switching operations per hour is Z>1, Fig. 27/1 or Fig. 27/2 (Wmax as a function of the number of switching operations per hour Z) applies. The Pmax and Wmax values are approximate values; they apply to applications where the brake is mounted between the B-face end shield of the motor and the motor fan or attached to the motor. The specified times apply to the following conditions: DC side brake switching, operating temperature, rated voltage, and rated air gap. All values are mean values that are subject to variation. In case of AC side brake switching, the coupling time t1 is substantially longer. The specified rated torques M2 characterise the torque level of the brakes. Depending on the application the brake is used for, the switching torque M1 and the transmissible torque M4 may differ from the specified M2 values. The switching torque M1 depends on the speed (rpm). If the friction surfaces (inner and/or outer discs) are contaminated with oil or grease the transmissible torque M4 and the switching torque M1 may drop. The technical specifications apply after the break-in process has been completed (see Table 26/2). Note: A current level corresponding to 70% of the rated current is reached if the brake is operated at rated voltage and at a coil temperature of 130 C. The required operating conditions specified in DIN VDE 0580 and the information provided in the CLASSIC LINE specification sheet and layout drawing must be observed during operation of the spring-applied multiple-disc brake! Specifications subject to change without notice! 11. Authorised repair shops for maintenance work Kendrion (Villingen) GmbH Industrial Drive Systems Wilhelm-Binder Straße 4-6 78048 Villingen-Schwenningen Tel. +49 7721 877-1417 Fax +49 7721 877-1462 Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 28 von 29
Betriebsanleitung 76 43119H03 Kendrion (Villingen) GmbH Wilhelm-Binder Straße 4-6 78048 Villingen-Schwenningen Deutschland Tel: +49 7721 877-1417 Fax: +49 7721 877-1462 sales-ids@kendrion.com www.kendrion.com Operating Instructions BA 77 100..A00 // Stand: 25.04.2016 // Page 1 von 29